OLYTECHNIC JAM
S P M
IT
N
U
Session :- May – June 2026
MECHANICAL
VITH SEMESTER
MAJOR PROJECT REPORT
ON
“PNEUMATIC SHEET METAL CUTTING
MACHINE”
SUBMITTED TO SUBMITTED BY
H.N. BHAT ( H.O.D ) SUMIT KUMAR
ROLL NO. – 8803
PROJECT GUIDE BRANCH : MECHANICAL
INDERJEET SIR
CERTIFICATE
This is to certify that the project report entitled "Pneumatic
Sheet Metal Cutting Machine" is a bonafide work carried out by
SUMIT KUMAR , Roll No. 8803 , under my direct supervision and
guidance.
This project is submitted in partial fulfillment of the
requirements for the award of DIPLOMA in MECHANICAL
ENGINEERING at NITS POLYTECHNIC for the session May – June
2026.
To the best of my knowledge, the matter embodied in this
report has not been submitted to any other Institute for the
award of any degree or diploma.
SIGNATURE
( H.O.D of Mechanical Engineering)
ACKNOWLEDGEMENT
I would like to express my deepest appreciation to all those who
provided me the possibility to complete this report. A special
gratitude goes to my project guide, INDERJEET SIR , whose
contribution in stimulating suggestions and encouragement
helped me through all the stages of fabrication and writing of
this project.
I also wish to express my gratitude to H.N. BHAT SIR (H.O.D) and
NITS POLYTECHNIC for providing me with a conducive
environment and the necessary facilities to complete this work.
Furthermore, I would like to acknowledge with much
appreciation the crucial role of the staff of MECHANICAL
DEPARTMENT , who gave the permission to use all required
equipment and the necessary materials to complete the tasks.
Last but not least, many thanks go to my family and friends for
their constant support and prayers, which kept me motivated
throughout this process.
CONTENT
• INTRREDODUCTION
• SHEET METAL
• SHEET METAL CUTTING
• COMPONENTS USED
• SPECIFICATION
• PNEUMATIC CYLINDERS
• DOUBLE ACTING CYLINDERS
• TWO-WAY DIRECT VALVE
• MATERIALS
• SHEARED EDGE
• SHEARING
• PNEUMATIC TRANSMISSION OF ENERGY
• CONTROL OF PNEUMATIC ENERGY
• CONTROL OF PRESSURE
• WORKING
• APPLICATIONS
• ADVANTAGES
• COST ESTIMATION
• PHOTOGRAPHY
ABSTRACT
We are using scissors for simple sheet metal cutting. It is
a manual method so that sheet metals are to be wasted
sometime because of mistakes happened such as wrong
dimensions etc., and also even a simple cutting may take
long [Link] machines are also available for sheet
metal cutting. But this method is used for only heavy
metal cutting and its cost is very high. We are using a
pneumatic system for sheet metal cutting in a easy way. It
is operated by a pneumatic hand lever of two way control
valve. Control valve is operated by a compressor
INTRODUCTION
SHEET METAL :
Sheet metal is simply a metal formed into thin and flat pieces. It is one of t
fundamental forms used in metal working and can be cut and bent into a varie of different
shapes. Countless everyday objects are constructed of the material. Thicknesses can vary
significantly, although extremely thin thicknesses are considered foil or leaf, and pieces
thicker than 6 mm (0.25 in) are considered plate.
Sheet metal is available in flat pieces or as a coiled strip. The coils are formed by
running a continuous sheet of metal through a roll slitter.
The thickness of the sheet metal is called its gauge. Commonly used steel sheet metal
ranges from 30 gauge to about 8 gauge. The larger the gauge number, the thinner the
metal. Gauge is measured in ferrous (iron based) metals while nonferrous metals such as
aluminum or copper are designated differently; i.e., Copper is measured in thickness by
Ounce.
There are many different metals that can be made into sheet metal, such
asaluminium, brass, copper, steel, tin, nickel and titanium. For decorative uses, important
sheet metals include silver, gold and platinum (platinum sheet metal is also utilized as a
catalyst.)
Sheet metal also has applications in car bodies, airplane wings, medical tables. roofs
for buildings (Architectural) and many other things. Sheet metal of iron and other materials
with high magnetic permeability, also known as laminated steel cores, has applications in
transformers and electric machines. Historically, an important use of sheet metal was in
plate armor worn by cavalry, and sheet metal continues to have many decorative uses,
including in horse tack. Sheet metal workers are also known as "Tin Bashers".("Tin
Knockers") which is derived from the hammering of panel seams when installing tin roofs.
There are three primary procedures in Layout
1. Parallel
2. Radial
3. Triangulation
SHEET METAL CUTTING :
Cutting processes are those in which a piece of sheet metal is separated by applying a great
enough force to cause the material to fail.
The most common cutting processes are performed by applying a shear force, and are
therefore sometimes referred to as shearing processes.
When a great enough shearing force is applied, the shear stress in the material will exceed
the ultimate shear strength and the material will fail and separate at the cut location.
This shearing force is applied by two tools, one above and one below the sheet. Whether
these tools are a punch and die or upper and lower blades, the tool above the sheet
delivers a quick downward blow to the sheet metal that rests over the lower tool.
A small clearance is present between the edges of the upper and lower tools, which
facilitates the fracture of the material. The size of this clearance is typically 2-10% of the
material thickness and depends upon several factors, such as the specific shearing process,
material, and sheet thickness.
The effects of shearing on the material change as the cut progresses and are visible on the
edge of the sheared material. When the punch or blade impacts the sheet, the clearance
between the tools allows the sheet to plastically deform and "rollover" the edge. As the tool
penetrates the sheet further, the shearing results in a vertical burnished zone of material.
Finally, the shear stress is too great and the material fractures at an angle with a small burr
formed at the edge. The height of these portions of the cut depends on several factors,
including the sharpness of the tools and the clearance between the tools.
COMPONENTS USED
➢ DOUBLE ACTING CYLINDER
➢ PNEUMATIC HAND OPERATED VALVE / SOLENOID
➢ HIGH SPEED STEEL BLADE
➢ AIR PUMP
➢ AC TO DC SUPPLY
SPECIFICATIONS
PNEUMATIC CYLINDER
Stroke Length = 80mm
Diameter = 25mm
Pressure = 40 bar to 140 bar
PNEUMATIC CYLINDER
Pneumatic cylinders (sometimes known as air cylinders) are mechanical devices
which use the power of compressed gas to produce a force in a reciprocating
linear motion.
Like hydraulic cylinders, pneumatic cylinders use the stored potential energy of a
fluid, in this case compressed air, and convert it into kinetic energy as the air
expands in an attempt to reach atmospheric pressure. This air expansion forces
a piston to move in the desired direction. The piston is a disc or cylinder, and the
piston rod transfers the force it develops to the object to be moved. Engineers
prefer to use pneumatics sometime because they are quieter, cleaner, and do
not require large amounts or space for fluid storage.
Because the operating fluid is a gas, leakage from a pneumatic cylinder will not
drip out and contaminate the surroundings, making pneumatics more desirable
where cleanliness is a requirement. For example, in the mechanical puppets of
the DisneyTiki Room, pneumatics are used to prevent fluid from dripping onto
people below the puppet.
DOUBLE – ACTING CYLINDER
Double-acting cylinders (DAC) use the force of air to move in both extend and
retract strokes. They have two ports to allow air in, one for out- stroke and one
for in-stroke. Stroke length for this design is not limited, however, the piston rod
is more vulnerable to buckling and bending. Addition calculations should be
performed as well by using design data hand book using some relations
between cylinder and pressure we can accurately find out bending and buckling
of tie rod.
2D VIEW :
TWO WAY DIRECTIONAL VALVE
A two-way directional valve consists of two ports connected to each otl
withpassages, which are connected and disconnected. In one extreme spo
position, portA is open to port B; the flow path through the valve is open. In th
other extreme,the large diameter of the spool closes the path between A and B;
the flow path isblocked. A two-way directional valve gives an on-off function.
(Flow path open and Flow path closed).
HIGH SPEED STEEL BLADE :
A blade is used to cut the sheet metal in a desired dimension. Here we are using
high speed steel blades to cut the sheet metal.
MATERIALS
STAINLESS STEEL :
The three most common stainless steel grades available in sheet metal are 304.
316. and 410.
Grade 304 is the most common of the three grades. It offers good corrosion
resistance while maintaining formability and weldability. Available finishes are
#2B, #3, and #4. Note that grade 303 is not available in sheet form.
Grade 316 offers more corrosion resistance and strength at elevated
temperatures than 304. It is commonly used for pumps, valves, chemical
equipment, and marine applications. Available finishes are #2B, #3, and #4.
Grade 410 is a heat treatable stainless steel, but does not offer as good
corrosion resistance. It is commonly used in cutlery. The only available finish is
dull.
SHEARED EDGE
A varietyof cutting processes that utilize shearing forces exist to separate or
remove material from a piece of sheet stock in different ways. Each process is
capable of forming a specific type of cut, some with an open path to separate
portion of material and some with a closed path to cut out and remove that
material. By using many of these processes together, sheet metal parts can be
fabricated with cut outs and profiles of any 2D geometry. Such cutting process
include the following
➢ Shearing - Separating material into two parts
➢ Blanking - Removing material to use for parts
➢ Conventional blanking
➢ Fine blanking
➢ Punching - Removing material as scrap
➢ Piercing
➢ Slotting
➢ Perforating
➢ Notching
➢ Nibbling
➢ Lancing
➢ Slitting
➢ Parting
➢ Cutoff
➢ Trimming
➢ Shaving
➢ Dinking
SHEARING
As mentioned above, several cutting processes exist that utilize shearing force to
cut sheet metal. However, the term "shearing" by itself refers to a specific
cutting process that produces straight line cuts to separate a piece of sheet
metal. Most commonly, shearing is used to cut a sheet parallel to an existing
edge which is held square, but angled cuts can be made as well. For this reason,
shearing is primarily used to cut sheet stock into Smaller sizes in preparation for
other processes. Shearing has the following capabilities
Sheet thickness: 0.005 - 0.25 inches
Tolerence: 0.1 inches
The shearing is performed on a shear machine, often called asquaring shear or
power shear, that can be operated manually or by hydraulic, pneumatic, or
electric power. A typical shear machine includes a table with support arms to
hold the sheet, stops or guides to secure the sheet, upper and lower straight -
edge blades, a gauging device to precisely position the sheet. The sheet is placed
between the upper and the lower blade, which are then forced together against
the sheet, cutting the material. In most devices, the lower blades remain
stationary while the upper blade is forced downward. The upper blade is slightly
offset from the lower blade, approximately 5 - 10% of the sheet thickness. Also
the upper blade is usually angled so that the cut progresses from one end to the
other, thus reducing the required force. The knife edge and are available in
different materials, such as low alloy steel and high carbon steel.
PNEUMATIC TRANSMISSION OF ENERGY:
The reason for using pneumatics, or any other type of energy transmission on a machine, is
to perform work. The accomplishment of work requires the application of kinetic energy to
a resisting object resulting in the object moving through a distance. In a pneumatic system,
energy is stored in a potential state under the form of compressed air. Working energy
(kinetic energy and pressure) results in a pneumatic system when the compressed air is
allowed to expand. For example, a tank is charged to 100 PSIA with compressed air. When
the valve at the tank outlet is opened, the air inside the tank expands until the pressure
inside the tank equals the atmospheric pressure. Air expansion takes the form of airflow.
To perform any applicable amount of work then, a device is needed which can supply an air
tank with a sufficient amount of air at a desired pressure. This device is positive
displacement compressor.
What a Positive Displacement Compressor Consists of
A positive displacement compressor basically consists of a movable member
insidea housing. The compressor has a piston for a movable member. The piston
is connected to a crankshaft, which is in turn connected to a prime mover
(electric motor, internal combustion engine). At inlet and outlet ports, valves
allow air to enter and exit the chamber.
How a Positive Displacement Compressor Works:
As the crankshaft pulls the piston down, an increasing volume is formed within
the housing. This action causes the trapped air in the piston bore to expand,
reducing its pressure. When pressure differential becomes high enough, the
inlet valve opens, allowing atmospheric air to flow in. With the piston at the
bottom of its stroke, inlet valve closes. The piston starts its upward movement to
reduce the air volume which consequently increases its pressure and
temperature. When pressure differential between the compressor chamber and
discharge line is high enough, the discharge valve opens, allowing air to pass into
an air receiver tank for storage .
Control of Pneumatic Energy:
Working energy transmitted pneumatically must be directed and under
complete control at all times. If not under control, useful work will not be done
and machinery or machine operators might be harmed. One of the advantages
of transmitting energy pneumatically is that energy can be controlled relatively
easily by using valves.
Control of Pressure:
Pressure in a pneumatic system must be controlled at two points after the
compressor and after the air receiver tank. Control of pressure is required after
the compressor as a safety for the system. Control of pressure after an air
receiver tank is necessary so that an actuator receives a steady pressure source
without wasting energy.
Control of Pressure after a Compressor:
In a pneumatic system, energy delivered by a compressor is not generally used
immediately, but is stored as potential energy in air receiver tank in the form of
compressed air.
In most instances, a compressor is designed into a system so that it operates
intermittently. A compressor usually delivers compressed air to a receiver tank
until high pressure is reached, then it is shut down. When air pressure in the
tank decreases, the compressor cuts in and recharges the tank. Intermittent
compressor operation in this manner is a power saving benefit for the system.
A common way of sensing tank pressure and controlling actuation and de-
actuation of relatively small (2-15 HP) compressors, is with a pressure switch.
WORKING
The pneumatic machine includes a table with support arms to hold the sheet, stops or
guides to secure the sheet, upper and lower straight - edge blades, a gauging device to
precisely position the sheet. The table also includes the two way directional valve. The two
way directional valve is connected to the compressor. The compressor has a piston for a
movable member. The piston isconnected to a crankshaft, which is in turn connected to a
prime mover (electricmotor, internal combustion engine). At inlet and outlet ports, valves
allow air toenter and exit the chamber. When the compressor is switched ON, the
compressed air is flow to inlet of the pneumatic cylinder.
The sheet is placed between the upper and the lower blade. The lower blade remains
stationary while the upper blade is forced downward. The upper blade is slightly offset from
the lower blade, approximately 5 - 10% of the sheet thickness. Also the upper blade is
usually angled so that the cut progresses from one end to the other, thus reducing the
required force.
When the pneumatic hand operated lever is moved forward, the piston starts moving in the
forward direction. The upper blade which are then forced against the sheet, cutting the
material. When the pneumatic hand operated lever is moved backward, the upper blade
will come to the original position (i.e., the upper blade will move upwards).
After the material is cut, adjust the pneumatic hand lever to the mid position (i.e., normal
position) and then the compressor is switched OFF.
APPLICATIONS
SHEET METALS ARE USED IN
➢ Car bodies
➢ Airplane wings
➢ Medical tables
➢ Roofs for buildings (Architectural) and many other things
➢ Sheet metal of iron and other materials with high magnetic permeability, also known
as laminated steel cores, has applications in transformers and electric machines.
➢ Historically, an important use of sheet metal was in plate armor worn by cavalry, and
sheet metal continues to have many decorative uses, including in horse tack.
ADVANTAGES
➢ Low cost
➢ Less consumption of time
➢ Easy to handle
➢ Skilled labor is not required
➢ Less maintainance
➢ High accuracy
➢ Good surface finish
➢ Less floor space
COST ESTIMATION
[Link] COMPONENTS COST IN RS
1 PNEUMATIC CYLINDER 2200.00
2 SHEET METAL ANGLE FRAME 1000.00
3 HAND OPERATED VALVE / SOLENOID 800.00
4 AIR PUMP 800.00
5 AC TO DC SUPPLY 700.00
TOTAL 5500.00
PHOTOGRAPHY